T20.3 - Isolated Single-Stage, Single-Phase AC-DC Rectifier for EV On-Board Chargers with Totem-Pole PFC, Secondary-Side Resonance, and Magnetic Integration

This paper proposes an isolated single-stage, single-phase AC/DC rectifier for EV onboard chargers that integrates a totem-pole PFC with a secondary-side resonant converter, enabling single-stage power conversion with reduced magnetic components. The PFC utilizes the transformer’s self-inductance to eliminate the need for a separate PFC inductor. At any given time, only two active devices conduct, minimizing conduction losses. During PFC operation, two devices perform low-frequency switching synchronized with the input voltage, while the other two achieve zero-voltage switching (ZVS), thereby suppressing switching losses. Simulations confirmed sinusoidal input current and ZVS operation. A compact 6 kW, 2.6 L prototype was developed and tested, demonstrating a sinusoidal input current with a THD of 3.3% and an efficiency of 97.1% at rated power.